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3D-printed orthoses
Overview

Innovative 3D printing technology

3D-printed inlay white

Make your insole business fit for the future.

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Logo CUBIX powered by SPRINGER

Learn how you can use innovative 3D printing technology to produce precise, customized orthopedic insoles yourself. 


We offer flexible solutions to efficiently and cost-effectively establish 3D-printed insoles in your company—depending on the size of your company and your individual requirements.

Benefits of 3D printing

Benefits
your customers will love.

Advantages of 3D printed insoles that your customers love
Next Generation Insoles

Sustainable
CUBIX insoles are produced locally or via a central 3D printing service. This process generates no unnecessary waste and makes you independent of long supply chains.

Recyclable
The insoles are made from TPU, which can be cleaned, melted down, and reprocessed into new filament for 3D printing. TPU, welches gereinigt, eingeschmolzen und zu neuem Filament für den 3D-Druck verarbeitet werden kann.

Customizable
Einzigartige, fließende Shorehärten von 20 - 80° Shore A garantieren eine komfortable und individuelle Anpassung auf die Patientenbedürfnisse.

Breathable
Visually, our insoles resemble a knitted pattern, they are open-pored and air-permeable and thus ensure better air circulation and a fresh foot climate.

3 ways – one goal.

What's the best way to start?

Quickstart – Order ready-made models from the online shop
→ The quick and easy introduction:
For anyone who wants to get started pragmatically. Get started right away at the POS—no effort, no risk. Ideal for businesses that don't want to waste time or change their processes.

Advantages:

  • Order inserts such as blanks directly from the web shop
  • 4 preconfigured models 
  • Sneaker/casual insole mold
  • Heel cup with 3 mm forefoot thickness
  • Black TPU, insole body 35° Shore A, soft pads 25° Shore A

Models

ZF 3D-01

flat foot – Longitudinal arch support, drop pad

ZF 3D-02

flat foot – Longitudinal arch support, drop pad, heel spur soft padding

ZF 3D-03

Pes planovalgus et abductus – Longitudinal arch support, drop pad, forefoot cushioning (metatarsal head II–III)

ZF 3D-04

Pes planovalgus et abductus – Longitudinal arch support, drop pad, heel spur soft bedding, forefoot cushioning (metatarsal head II–III)

✔ Centralised production by Springer 
(service within 48h)
Webshop
FlexConfig – configuration without CAD design

→ More influence, minimal effort – easy to configure, no paperwork: 

For anyone who wants to customise but doesn't want to use CAD. Use the digital form to specify the shape, height and soft bedding – quickly, clearly structured and without time-consuming screen work. For everyone who prefers to be in the workshop rather than sitting in front of a computer.

Advantages:

  • Interaktives PDF-Konfigurationsformular
  • Sneaker- und Sportform zur Auswahl
  • Fersenmulde in 2, 3, 5 mm Vorfußstärke
  • TPU schwarz, Einlagenkörper 35°/Weichbettungen 25° Shore A 
  • Alle Pelottenformen mit individuellen Höhenabstufungen 
  • Optional leichter Toe bridge
✔ Centralised production by Springer 
(service within 48h)
PDF order form

→ Full customisation – design directly on the scan or pedography:

For digitally savvy engineers who want 100% control but don't need to be CAD professionals. A fully customised insole in just a few clicks: design the shape, function and material composition to fit perfectly. Ideal for businesses that want to integrate 3D treatments professionally and digitally – with maximum flexibility and minimum effort.

Advantages:
  • Use the CAD Easycad Basic Module
  • 7 insole shapes – from narrow to comfortable
  • TPU white, Shore hardness freely selectable
    incl. smooth transitions
  • Heel cup, inner/outer elevations (also rear foot only), heel mould
  • Intuitive operation – can also be used directly in customer meetings
  • Optional centralised production or
    printing on your own printer
✔ Centralised production by Springer 
(service within 48h)
✔ In-house production
(own printer)
More about EASYCAD
Application

Which target group
would you like to reach?

Illustration forefoot painIllustration of hindfoot painIllustration knee complaints

Everyday life

For patients with everyday complaints such as foot, knee or back pain

Treatment goals:

Support for the longitudinal arch in case of misalignment
Support for instabilities
Improved knee support

We recommend

Diabetes illustration

Diabetes

For patients with diabetic foot syndrome

Treatment goals:

Pressure redistribution to avoid pressure peaks
Perfect fit thanks to adaptation with 3D foot scan
Individual soft bedding of vulnerable areas

We recommend

Starter Kit 2 for EASYCAD
Production strategy

Would you like to invest
or try it out first?

Which solution is right for you?

Whether you are a beginner or an experienced producer - with our flexible solutions, you will find the perfect strategy for your digital insole production. Get advice and step into the digital future of 3D printing.

Solution 1
Centralised production

3D printing centralised production

No risk, no high investments
No expertise or maintenance required

3 ways to order:

SPRINGER takes care of production and shipping
Solution 2
Own printer
GP Mike 3D printer

Printing with GP Mike

Set standards in your region as an innovative supplier
No dependencies
You design your insoles as usual in EASYCAD
You produce independently without waiting times
More about GP Mike
Counselling

Do you have further questions?

Your contacts for 3D printing

We will be happy to advise you on choosing the right hardware for your company or put together an individual offer for you.

Contact persons

Take control: master your production with in-house manufacturing

Dominate your regional market by relocating production in-house. Free yourself from the unpredictability of external suppliers and supply chains. This autonomy not only enables you to react quickly to customer requirements, but also puts you in control of your own production processes. Say goodbye to external dependencies and retain full control over your production processes.
Benefit from our advanced manufacturing technology and in-depth expertise in orthopaedic technology. With Springer, you get more than just state-of-the-art equipment - you have access to the accumulated knowledge and innovative spirit of an innovation leader. Our commitment to continuous technological advancement drives new developments that go into every one of our products.
Strengthen your business with the efficiency that comes with in-house production. Reduce costs, increase productivity and keep a firm grip on your budget. Future-proof your operations with complete control and monitoring of your manufacturing processes.
Rely on the solution from the market leader with CUBIX Mike 3D technology & the optimum EASYCAD software from Springer for smooth production processes and the best results for your customers.
Wussten Sie, dass Sie die Einlagen auch über unsere zentrale Fertigung herstellen lassen können? Nutzen Sie hierzu unsere zentrale EASYCAD Fertigung!

Become independent with the GP Mike 3D inlay printer:

Revolutionise your orthopaedic workshop with clean, virtually dust-free production!
3D printing technology enables you to produce insoles directly on site with an optimum fit for your customers without having to rely on external suppliers. Position yourself as a trendsetter in your region and utilise the benefits of 3D printing to take your business to the next level.
3D printing is not only seen as a pioneering technology in manufacturing, but also as an environmentally friendly solution. The materials used are fully recyclable, thus contributing to sustainable production. Produce 3D-printed inlay blanks with the GP Mike 3D printer.
The production process is optimised by transferring the print data directly from the Easycad design program to the printer. The precise print quality ensures that the insert is ready for use immediately after printing and only needs to be covered.
Invest in the future of your orthopaedic trade and benefit from the flexibility and efficiency of the GP Mike 3D insole printer. Show your customers that you have your finger on the pulse and rely on sustainable, innovative technologies.

Basics and technology

3D printing is revolutionising many areas of industry, and the production of orthopaedic insoles is no exception. This technology enables the precise production of insoles that are perfectly customised to the individual anatomical characteristics of each foot. At the heart of the process are 3D printers that convert digital designs into physical objects layer by layer. By using the advanced EASYCAD design software from Springer, orthopaedic technicians can design the 3D insoles exactly according to the patient's needs. Various printing techniques are used for this. One of these is selective laser sintering (SLS) or the effective FFF 3D printing process. This allows completely customised models to be produced using the 3D printing process.
Benefit from the advantages of FFF technology for customised orthopaedic solutions
In the evolving field of orthopaedic insole production, Fused Filament Fabrication (FFF) technology stands out as ground-breaking. This 3D printing method utilises the versatility of thermoplastic filaments to provide customised and precise solutions for the production of orthopaedic insoles. Here are the reasons why FFF technology is revolutionising the field:

1. exceptional adaptability: FFF enables a high degree of customisation in interlining production. By customising the settings and using different filament types, you as our partner can create insoles that meet the specific contours and flexibility requirements of individual users. This customisability ensures that each insole provides optimal support and comfort, tailored to the needs of the wearer.

2. cost efficiency: FFF equipment usually requires a lower initial investment compared to other 3D printing technologies such as SLS. The materials used in FFF, such as PLA, ABS and TPU, are not only inexpensive but also readily available, which lowers production costs. This makes FFF an excellent choice for orthopaedic practices looking to integrate in-house manufacturing.

3. speed and accessibility: FFF printers are known for their speed and ease of use, making them ideal for clinical environments. They enable fast production cycles, meaning orthopaedic clinics can produce insoles on demand, reducing waiting times for patients and streamlining the treatment process.

4. wide selection of materials: The range of materials compatible with FFF technology is constantly expanding, including options that are specifically suitable for medical use. Materials such as TPU provide the necessary flexibility and durability for orthopaedic insoles and ensure comfort and longevity in use.

By integrating Springer's FFF 3D printing into their production processes, orthopaedic specialists can not only improve the quality and effectiveness of their insoles, but also bring innovation and efficiency to their operations. FFF opens up new possibilities for patient care and makes personalised orthopaedic solutions more accessible.

The choice of material plays a decisive role in the functionality and comfort of 3D-printed insoles. Various materials such as TPU (thermoplastic polyurethane), polyamide and even advanced composite materials are available. Each material offers different properties in terms of flexibility, durability and comfort. TPU, for example, is known for its flexibility and wear resistance, making it an excellent choice for insoles that need to provide both support and cushioning. Choosing the right material depends on the specific requirements of the insoles and the preferences of the end user.

The manufacturing process

The production process for 3D-printed insoles begins with a detailed digital scan of a patient's feet. This scan captures all the nuances of the foot structure to ensure that the final product fits perfectly. The data from the scan is used to create a customised design using advanced CAD software. Once the design is finalised, it is sent to a 3D printer, which applies materials layer by layer to build the insole. This additive manufacturing process allows for complex designs that are difficult to achieve with traditional manufacturing methods. After printing, the insoles are cleaned, finished and sometimes reworked to improve durability and comfort.
Efficiency in 3D printing is critical to scaling production and reducing costs. Optimising print jobs involves several strategies, such as adjusting print settings for speed and material consumption, using Springer's state-of-the-art EASYCAD software to control the printing process and organising print jobs to maximise printer utilisation. In addition, ongoing maintenance of the 3D printers ensures that they operate at maximum efficiency.
3D design has changed the way foot orthoses are made. With 3D CAD software EASYCAD, specialist companies can quickly iterate designs based on specific patient needs or feedback. This flexibility enables rapid prototyping - changes can easily be made without the need for expensive moulds or tooling. 3D design also enables the integration of complex features into the insoles, such as customised support structures or areas of varying density that provide different levels of cushioning and support where they are needed. This capability not only improves the functionality of the insoles, but also increases comfort and treatment outcomes for the patient.

Applications and practical use

3D-printed insoles bring a new level of customisation and comfort to foot care. Using precise 3D scans of the patient's feet, these insoles are customised to fit the unique contours and biomechanical requirements of each individual. This customisation helps to distribute pressure evenly across the foot, reducing the risk of pressure points and improving overall foot comfort. Additionally, the ability to incorporate variable densities and targeted support into the insole design further enhances the comfort and effectiveness of the insoles, making everyday activities more comfortable and less painful for people with foot-related problems.
In the field of orthopaedics, 3D-printed insoles are becoming increasingly important due to their precision and adaptability. These insoles are particularly beneficial for patients with specific orthopaedic conditions such as flat feet, high arches or diabetic foot complications. By providing support exactly where it is needed most, these insoles can help bring the foot and ankle into a more natural position, reducing stress on other parts of the musculoskeletal system. Orthopaedic surgeons and podiatrists are now recommending 3D printed insoles as an essential part of comprehensive treatment plans for various foot conditions. With the complete CUBIX MP Mike & EASYCAD solution from Springer, you can benefit from this technology for the benefit of your patients.
The introduction of 3D printing technology has made it possible to produce customised insoles that fit the unique shape of each foot perfectly. This technology allows for rapid production and iteration, meaning that insoles can be customised not only for the shape of the foot, but also for specific activities or shoe types. Whether for athletic performance, everyday comfort or therapeutic needs, 3D printed insoles can be designed to meet the diverse requirements of all users. This level of personalisation ensures that each pair of insoles is as effective as possible, providing just the right amount of support and cushioning where it is needed most.

Special topics and innovations

Innovations are shaping the production of 3D-printed insoles by finding new ways to improve quality and efficiency. The use of advanced design software makes it possible to develop complex and customised insoles that are specifically tailored to the user's biomechanical requirements. The ability to quickly create prototypes significantly speeds up the development process and allows teams to bring innovative solutions to market faster. These agile methods lead to continuous improvement of the product range and drive technological development in the industry.
The development of 3D-printed insoles is a complex process that requires close collaboration between different specialisms. Our engineers, designers and medical professionals work together to develop products that meet the highest quality standards. Modern software solutions play a crucial role in this process by making it possible to optimise designs and increase production efficiency. By using software for simulation and analysis, problems can be identified and solved at an early stage, which shortens development times and improves product quality.
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